Air compressor enclosed in shroud having tab isolator

ABSTRACT

The present invention is directed to an air compressor enclosed in a shroud with plastic tab isolators. In an exemplary aspect of the present invention, an air compressor may include an air tank for containing air at an elevated pressure, and a shroud for enclosing the air tank. The shroud may include a ribbing and a plurality of support members. The ribbing and the plurality of support members may be in contact with the air tank to assist in holding the air tank inside the shroud.

CROSS-REFERENCE TO RELATED DOCUMENTS

The present application claims the benefit under 35 U.S.C. § 119(e) ofU.S. Provisional Patent Application Ser. No. 60/459,804, entitled “AirCompressor Enclosed in Shroud with Plastic Tab Isolator,” filed Apr. 2,2003. Said U.S. Provisional Patent Application Ser. No. 60/459,804 isherein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to air compressors andparticularly to an air compressor enclosed in a shroud having tabisolators.

BACKGROUND OF THE INVENTION

Air compressors are widely used in household and industrial applicationsfor operating air powered tools such as fasteners, socket driving tools,material shapers, sanders, sprayers, inflation chucks, and the like. Anair compressor typically includes an air tank for storing compressedair, a compressor for supplying compressed air to the air tank, and amanifold assembly for controlling and distributing compressed air fromthe portable air compressor to one or more air powered tools.Conventionally, a portable air compressor may include a shroud orhousing, which encloses the air tank, the compressor, and the manifoldassembly. The shroud, which is preferably formed of plastic, may includea handle for allowing an operator to lift and transport the portable aircompressor between worksites.

An air tank enclosed in a shroud of an air compressor conventionally hasa known tolerance due to the manufacturability of the tank head and thewelding process of the tank. This tolerance often leads to thedifficulty in designing a general-purpose shroud ribbing that may firmlyhold air tanks of a range of sizes in place. In other words, if theribbing is designed to firmly hold a nominal tank (e.g., an air tankwith a medium tolerance) in place, there would be an extra space betweenthe tank and the shroud for a minimum tolerance tank (thus the minimumtolerance tank may move in the shroud); on the other hand, a maximumtolerance tank would not fit inside the ribbing at all. This often leadsto manufacture inefficiency.

Thus, it would be desirable to provide an apparatus and method forsecuring air tanks of a range of sizes within a known tolerance inside ashroud of an air compressor.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to an air compressorenclosed in a shroud with plastic tab isolators. In an exemplary aspectof the present invention, an air compressor includes an air tank forcontaining air at an elevated pressure, and a shroud for enclosing theair tank. The shroud may include a ribbing and a plurality of supportmembers. The ribbing and the plurality of support members may be incontact with the air tank to assist in holding the air tank inside theshroud.

In an additional exemplary aspect of the present invention, a portableair compressor includes an air tank for containing air at an elevatedpressure, and a shroud for enclosing the air tank. The shroud mayinclude a ribbing and a plurality of support members. The ribbing mayinclude a first group of ribs and a second group of ribs. The firstgroup of ribs may be perpendicular to the second group of ribs. Theribbing and the plurality of support members may be in contact with theair tank to assist in holding the air tank inside the shroud.

In another exemplary aspect of the present invention, a shroud forenclosing an air tank of an air compressor includes a ribbing extendingfrom an inner wall of the shroud, and a plurality of support membersextending from the inner wall of the shroud. The ribbing may include afirst group of ribs and a second group of ribs. The ribbing and theplurality of support members may be in contact with the air tank toassist in holding the air tank inside the shroud.

In a further exemplary aspect of the present invention, a method forholding air tanks of a range of sizes inside a shroud of an aircompressor may include the following steps: (a) placing a ribbing on aninner wall of the shroud so that the ribbing may hold an air tank of amaximum size; and (b) placing a plurality of support members on theinner wall so that the plurality of support members may hold an air tankof a minimum size.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the invention as claimed. The accompanyingdrawings, which are incorporated in and constitute a part of thespecification, illustrate an embodiment of the invention and togetherwith the general description, serve to explain the principles of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The numerous advantages of the present invention may be betterunderstood by those skilled in the art by reference to the accompanyingfigures in which:

FIG. 1 is an isometric view illustrating an air compressor in accordancewith an exemplary embodiment of the present invention;

FIG. 2 is a cut-away view of the portable air compressor assembly shownin FIG. 1, showing an air tank, a shroud ribbing and a support member;

FIG. 3 further illustrates the air tank, the shroud ribbing, and thesupport member shown in FIG. 2;

FIG. 4 illustrates the shroud ribbing and the support member shown inFIG. 2 in accordance with an exemplary embodiment of the presentinvention;

FIG. 5 is a partial view of the shroud ribbing and the plurality ofsupport members shown in FIG. 4; and

FIG. 6 is a partial right elevation view of the air compressor shown inFIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings.

An air tank enclosed in a shroud of an air compressor conventionally hasa known tolerance due to the manufacturability of the tank head and thewelding process of the tank. This tolerance often leads to thedifficulty in designing a general-purpose shroud ribbing that may firmlyhold air tanks of a range of sizes in place. In other words, if theribbing is designed to firmly hold a nominal tank (e.g., an air tankwith a medium tolerance) in place, there would be an extra space betweenthe tank and the shroud for a minimum tolerance tank (thus the minimumtolerance tank may move in the shroud); on the other hand, a maximumtolerance tank would not fit inside the ribbing at all. This often leadsto manufacture inefficiency. One purpose of the present invention is toaddress this problem.

Referring generally now to FIGS. 1 through 7, an exemplary portable aircompressor 100 in accordance with the present invention is shown. Theportable air compressor 100 may include an air tank 104 for storingcompressed air, a compressor for supplying compressed air to the airtank 104, and a manifold assembly for controlling and distributingcompressed air from the portable air compressor 100 to one or more airpowered tools. The portable air compressor 100 may include a shroud orhousing 102, which encloses the air tank 104, the compressor, and themanifold assembly. The shroud 104, which is preferably formed ofplastic, may include a handle for allowing an operator to lift andtransport the portable air compressor 100 between worksites. The shroudmay include a ribbing 108 extending from an inner wall 106 of the shroud102. The ribbing 108 may include a first group of ribs 112 in a firstdirection and a second group of ribs 114. Preferably, the first group ofribs 112 intersects and is perpendicular to the second group of ribs 114(see, e.g., FIGS. 4-6). The first group of ribs 112 and the second groupof ribs 114 may be configured based on the shape of the air tank 104.For example, the first group of ribs 112 and the second group of ribs114 may be at least partially contoured to generally conform to arounded tank. In a preferred embodiment, the ribbing 108 may be sodesigned that the ribbing 108 may hold a maximum tolerance tank (i.e.,an air tank of a maximum size within a known tolerance). Thus, any airtank within the known tolerance may fit inside the ribbing 108. However,this may generate an extra space between the shroud 102 and the tank 104for a tank that is not at the high end of the tolerance.

According to an aspect of the present invention, the shroud 102 mayinclude a plurality of support members 110 extending from the inner wall106 of the shroud 102. Preferably, the plurality of support members 110are made of plastic. Thus, the flexibility inherent in the plastic maybe utilized to design the shroud 102 that firmly holds an air tank 104within a known tolerance. The plurality of support members 110 may beshaped like tabs, or the like. Each of the plurality of support members110 may be positioned between a rib belonging to the first group of ribs112 and a rib belong to the second group of ribs 114. Preferably, theplurality of support members 110 may be symmetrically positioned so asto secure the tank 104 uniformly. The plurality of support members 100may be so designed that the plurality of support members 100 may firmlyhold a minimum tolerance tank (i.e., an air tank of a minimum sizewithin a known tolerance).

By creating the ribbing 108 that may hold a maximum tolerance tankwithin a known tolerance and the plurality of support members 110 thatmay hold a minimum tolerance tank within the known tolerance, the shroud102 of the present invention thus may firmly hold any tank within theknown tolerance. This may increase manufacture efficiency. Because theplurality of support members 110 surrounds and interferes with the tank104, the tank 104 may be maintained in place by the flex of the plastic,and any gap between the tank 104 and the shroud 102 may be taken up bythe flex of the plurality of support members 110. Moreover, if the aircompressor 100 is dropped to the ground or placed on its side, theplurality of support members 110 may spring accordingly to take up thegap on the needed side. Additionally, if the air compressor movement istoo violent, then the ribbing 108 may prevent the tank 102 from movingtoo far.

It is understood that the specific order or hierarchy of steps in theprocesses disclosed is an example of exemplary approaches. Based upondesign preferences, it is understood that the specific order orhierarchy of steps in the processes may be rearranged while remainingwithin the scope of the present invention. The accompanying methodclaims present elements of the various steps in a sample order, and arenot meant to be limited to the specific order or hierarchy presented.

It is believed that the present invention and many of its attendantadvantages will be understood by the foregoing description. It is alsobelieved that it will be apparent that various changes may be made inthe form, construction and arrangement of the components thereof withoutdeparting from the scope and spirit of the invention or withoutsacrificing all of its material advantages, the form herein beforedescribed being merely an explanatory embodiment thereof.

1. An air compressor, comprising: an air tank for containing air at an elevated pressure; a shroud for enclosing said air tank, said shroud including a ribbing and a plurality of support members, wherein said ribbing and said plurality of support members may be in contact with said air tank to assist in holding said air tank inside said shroud.
 2. The air compressor of claim 1, wherein said plurality of support members are made of plastic.
 3. The air compressor of claim 1, wherein said ribbing is made of plastic.
 4. The air compressor of claim 1, wherein said ribbing comprises a first group of ribs in a first direction and a second group of ribs in a second direction.
 5. The air compressor of claim 4, wherein said first direction is perpendicular to said second direction.
 6. The air compressor of claim 4, wherein said first group of ribs intersects said second group of ribs.
 7. The air compressor of claim 4, wherein each of said plurality of support members is in contact with one of said first group of ribs and one of said second group of ribs.
 8. A portable air compressor, comprising: an air tank for containing air at an elevated pressure; a shroud for enclosing said air tank, said shroud including a ribbing and a plurality of support members, said ribbing comprising a first group of ribs and a second group of ribs, said first group of ribs being perpendicular to said second group of ribs, wherein said ribbing and said plurality of support members may be in contact with said air tank to assist in holding said air tank inside said shroud.
 9. The portable air compressor of claim 8, wherein said plurality of support members are made of plastic.
 10. The portable air compressor of claim 8, wherein said ribbing is made of plastic.
 11. The portable air compressor of claim 8, wherein each of said plurality of support members is in contact with one of said first group of ribs and one of said second group of ribs.
 12. The portable air compressor of claim 8, wherein said plurality of support members are symmetrically positioned.
 13. A shroud for enclosing an air tank of an air compressor, comprising: a ribbing extending from an inner wall of said shroud, said ribbing including a first group of ribs and a second group of ribs; and a plurality of support members extending from said inner wall of said shroud, wherein said ribbing and said plurality of support members may be in contact with said air tank to assist in holding said air tank inside said shroud.
 14. The shroud of claim 13, wherein said plurality of support members are made of plastic.
 15. The shroud of claim 13, wherein said ribbing is made of plastic.
 16. The shroud of claim 13, wherein each of said plurality of support members is in contact with one of said first group of ribs and one of said second group of ribs.
 17. The shroud of claim 13, wherein said first group of ribs is perpendicular to said second group of ribs.
 18. The shroud of claim 17, wherein said plurality of support members are symmetrically positioned.
 19. A method for holding air tanks of a range of sizes inside a shroud of an air compressor, comprising: placing a ribbing on an inner wall of said shroud so that said ribbing may hold an air tank of a maximum size among said air tanks of a range of sizes; and placing a plurality of support members on said inner wall so that said plurality of support members may hold an air tank of a minimum size among said air tanks of a range of sizes.
 20. The method of claim 19, wherein said ribbing comprises a first group of ribs and a second group of ribs, said first group of ribs being perpendicular to said second group of ribs.
 21. The method of claim 20, wherein each of said plurality of support members is in contact with one of said first group of ribs and one of said second group of ribs.
 22. The method of claim 21, wherein said plurality of support members are symmetrically positioned. 